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TABLE OF CONTENTS

Consumer Safety & Warranty Information . . . . 1Installation Instructions . . . . . . . . . 2Spare Parts List . . . . . . . . . . . 3Exploded View . . . . . . . . . . . 4Maintenance & Disassembly. . . . . . . . 6Inspection. . . . . . . . . . . . . 8Re-assemble . . . . . . . . . . . 8Inner Fork Leg, Crown. & Brake Arch . . . . . 9Adjusting the Ride Qualities. . . . . . . . 10Trouble Shooting. . . . . . . . . . . 11

ANSWER PRECISION SUSPENSION

CONGRATULATIONS FOR CHOOSING THE LATEST STATE OF THE ART MOUNTAIN BIKE SUSPENSION FORKAVAILABLE. THE 2000 SX FORK MODELS HAVE STATE OF THE ART MCU/SPRING COMPRESSION SYSTEMS. THE SXSERIES ALL USE THE NEW TWIN PISTON CARTRIDGE SYSTEM (TPC) THAT SURPASS ALL OTHER TYPES OF OILDAMPED SYSTEM IN PERFORMANCE AND DURABILITY.

Your 2000 SX Fork is fully assembled and ready to be installed onto your bicycle and comes equipped with a 1 1/8” threadless steer tube.2000 SX’s are available with the V-Brake cable hangerless arch and have an optional attachable cable hanger kit P/N 85-3800, which isavailable through your dealer.

CONSUMER SAFETY INFORMATION

GENERAL WARNING: Bicycling is a hazardous activity that requires that the rider stay in control of his or her bicycle at all times.Reading this manual entirely and properly maintaining your bicycle and suspension fork and rear shock will reduce the possibility ofinjury or possible death. Prior to riding your bicycle, you should inspect your suspension fork and shock to ensure that no damagehas occurred during the course of riding. Do not ride your bicycle if the fork or shock shows any signs of bending, cracking, leaking,or if it is missing any of the originally supplied components. Any fall from your bicycle can result in serious injury or even death.Following these instruction can help you reduce the risk of being injured.

If you are a moderate or aggressive off-road rider, or ride at least three times a week over rough terrain, Answer recommendsreturning your suspension fork or shock every 2 years for a though inspection and update. Take your fork to a Manitou authorizeddealer who can arrange for shipment to Answer Products, or you may call Answer to have your fork shipped directly at (661) 257-4411.

IMPORTANT: The 2000 SX Fork is a off road fork and as such, does come with the reflectors for on road use installed. Reflectorbracket kit P/N 85-3674 is available through your dealer. Have your dealer or mechanic install the kit to meet the Consumer ProductSafety Commission's (C.P.S.C.) Requirements for Bicycles if the fork is going to be used on public roads at any time. If you havequestions regarding C.P.S.C. Standards contact your dealer.

1. Never remove or have the steer tube or stanchions (inner legs) removed from the crown. The steer tube and stanchions are press fitassembled at the factory. Pressing them out will permanently damage the crown, steer tube, and stanchions beyond repair and renderthem unsafe for any continued use.

2. Never attempt to thread a threadless steer tube. Machining threads will weaken the steer tube and cause unsafe condition. The only safething to do is obtain the proper crown/steerer from your dealer.

3. Any other alterations or modifications to your fork should be considered unsafe. Contact Answer products Technical Support prior tomodifying your fork in any way for safety information.

4. Do not use any Manitou Fork if any part appears to be broken, bent, cracked, or damaged. Contact your dealer or Answer ProductsTechnical Support, (800) 670-7446, if you have any questions concerning the integrity, condition, or safe operation of your fork.

5. Answer Products recommends that you periodically inspect your fork for wear and damage. Inspect the Crown, Inner Legs, and OuterLeg Dropout and Brake Arch areas for cracks or damage. Before every ride check to ensure that the proper preload exists and that thepositive rebound stop is in order to ensure that the fork can not over extend.

WARRANTY INFORMATIONAny Answer Products fork found by the factory to be defective in materials and/or workmanship within one year from the date of purchasewill be repaired or replaced at the option of the manufacturer, free of charge, when received at the factory, freight prepaid. This warranty doesnot cover breakage, bending, or damage that may result from crashes or falls. This warranty does not cover any fork that has been modified,subject to misuse or whose serial number has been altered, defaced or removed. This warranty does not cover paint damage. Anymodifications made by the user will render the warranty null and void. This warranty is expressly in lieu of all other warranties, and anyimplied are limited in duration to the same duration as the expressed warranty herein. Answer Products shall not be liable for any incidental orconsequential damages.

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If for any reason warranty work is necessary, return the fork to the place of purchase. In the USA, dealers should call Answer Products for areturn authorization number (RA#). At that time instructions for repair, return, or replacement shall be given. Customers in countries otherthan USA should contact their dealer or local distributor.

INSTALLATION INSTRUCTIONS

Figures 1,2, &3Insure that the proper steer tube has been delivered on your fork.The steer tube may need to be cut to length to fit your bicyclehead tube. If you are not familiar with this procedure or do nothave the proper tools to cut the steer tube it is recommended thatyou seek a dealer with a qualified bicycle mechanic to performinstallation.

WARNING: The steer tube and stanchions (inner legs) are aone time precision press fit at the factory and cannot beremoved from the crown. Replacement of the entirecrown/steerer assembly must be done to change steer tubelengths or diameters. Removing and replacing the steer tubeor stanchions will result in an unsafe condition and shouldnever be done.

1. Remove old forks from bicycle.2. Measure and cut the steer tube to fit your bicycle head tube.3. Remove crown race from old forks and press onto 2000 SX

Steer until seated on crown.4. Clean and grease headset bearing and races of bicycle.5. Install lower bearings on fork crown race.6. Install steer tube into head tube frame.7. Install upper bearing, spacers, and stem.8. Install stem cap, adjust and tighten headset per

manufacturer’s instructions.9. Install handlebars to desired height. Torque stem handlebar

pinch screw and stem clamping system to manufacturer’sinstructions.

10. Install cantilever breaks and adjust to pre manufacturersinstructions.

11. Adjust fork wheel quick release to clear the 0.275” (7MM)thick secondary catch dropout. The quick release must betightened after it is adequate thread engagement (4 or morethreads with the release adjusted to bicycle per manufacturersspecifications.

12. Install brake cable per manufacturers instructions.

Note: All 2000 SX Forks are equipped with a secondary catchdropout.

Note: The 2000 SX comes equipped with a hangerless arch.Brake cable hangers that attach to the arch are availablethrough your dealer. See Figure 2

FIGURE 1: RACE INSTALLATION

FIGURE 2: BRAKE CABLE ROUTING

WARNING: When installing wheel or any new tire check the minimum tire clearance. Measure from the highest point on the tire tothe bottom of the crown. The minimum clearance allowed is 3.268”(83.0MM) travel. Any less clearance can result in accidentresulting in serious injury or death. Figure 3

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FIGURE 3: TIRE CLEARANCE

SPARE PARTS: Table 1Spare parts can be ordered through your local dealer. If you have any problems that you cannot resolve with your dealer, you may call AnswerProducts Technical / Warranty Service Department at (805) 257-4411, 8:00 AM to 5:00 PM, Pacific Standard, Monday through Friday. Inaddition helpful information can be found on the Answer Products Web Site, http://www.answerproducts.com. Include on the site is downloadable manuals and e-mail to technical support.

DESCRIPTION PART NUMBER SX CROWN, 1X6.5 CM 85-3788SX CROWN, 1X7.5 CM 85-3789SX CROWN, 1X5.5 CM 85-3790SX CROWN, 1X8.5 CM 85-3791SX CROWN, 1X10.5 CM 85-3792SX CROWN, 1X12.5 CM 85-3793SX CROWN, 1 1/8”X5.5 CM 85-3794SX CROWN, 1 1/8”X6.5 CM 85-3795SX CROWN, 1 1/8”X7.5 CM 85-3796SX CROWN, 1 1/8”X8.5 CM 85-3797SX CROWN, 1 1/8”X10.5 CM 85-3720SX CROWN, 1 1/8”X12 THRDLS CM 85-3720SX CROWN, 1 1/8”X12 ALLOY 85-3800SX BRAKE HANGER KIT 85-3801MANITOU PREP M GREASE, 6 OZ. 85-3810MICRO LUBE GREASE GUN HEAD 85-3812MRD SUSPENSION FULID, 5WT., 8OZ. 85-3814MAXIMA 7.5WT SUSPENSION FLUID, 8 OZ. 85-3820MAXIMA 10WT SUSPENSION FLUID, 8OZ. 85-3822SX BUSHING SEAL KIT 85-38272000 BUSHING SIZE TOOL 85-39112000 SX LT FIREBALL STICKER KIT 85-40842000 SX LT BLACK STICKER KIT 85-40852000 SX RED STICKER KIT 85-40862000 SX BLUE STICKER KIT 85-40872000 SX R BLACK STICKER KIT 85-40882000 SX R YELLOW STICKER KIT 85-40892000 LOC-OUT KIT SX AND SX R 85-89892000 ADJUSTER KIT SX, X-VERT 85-90732000 ADJUSTER KIT SX LT 85-91042000 ADJUSTER KIT SX 85-91052000 SX LT LOWER SHAFT ASSY 85-91082000 SX LT UPPER SHAFT ASSY 85-9109

DESCRIPTION PART NUMBER2000 SX LOWER SHAFT ASSEMBLY 85-91102000 SX UPPER SHAFT ASSEMBLY 85-91112000 SX R LOWER SHAFT ASSEMBLY 85-91122000 SX R UPPER SHAFT ASSEMBLY 85-91132000 FIREBALL SX OUTER ASSEMBLY W/O STICKERS 85-91182000 BLACK SX OUTER ASSEMBLY W/O STICKERS 85-91192000 BLUE SX OUTER ASSEMBLY W/O STICKERS 85-91202000 RED SX OUTER ASSEMBLY W/O STICKERS 85-91212000 YELLOW SX OUTER ASSEMBLY W/O STICKERS 85-91222000 SX SOFT RIDE KIT 85-9127

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2000 SX STOCK RIDE KIT 85-91282000 SX FIRM RIDE KIT 85-91292000 SX LT STEER/LEG KIT 85-91312000 SX STEER/LEG KIT 85-91322000 SX R STEER LEG/KIT 85-91332000 COBALT SX OUTER ASSEMBLY W/O STICKERS 85-91342000 WHITE SX OUTER ASSEMBLY W/O STICKERS 85-91382000 GREEN SX OUTER ASSEMBLY W/O STICKERS 85-91392000 COBALT SX R OUTER ASSEMBLY W/O STICKERS 85-91452000 TREK COBALT SX STICKER KIT 85-91482000 COMMENCAL WHITE SX STICKER KIT 85-91592000 DECATHALON WHITE SX STICKER KIT 85-91602000 SPECIALIZED BLACK SX STICKER KIT 85-91612000 MERIDA COBALT SX LT STICKER KIT 85-91632000 GIANT USA YELLOW SX STICKER KIT 85-91642000 SCOTT SX LT KAW. GREEN STICKER KIT 85-91652000 SPECIALIZED FIREBALL SX R STICKER KIT 85-91682000 SPECIALIZED RED SX R STICKER KIT 85-91692000 SPECIALIZED RED SX LT W/ALLOY STICKER KIT 85-9171

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MAINTENANCE

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IMPORTANT: The 2000 SX should not be used if any parts appear to be or are damaged. Contact your local dealer or AnswerProducts for replacement parts.

IMPORTANT: Use of fork boots is required to keep your 2000 SX performing well and your warranty in effect. Use of this forkwith the boots removed will shorten the life of the fork, reduce the performance and void the warranty.

Your 2000 SX Fork requires periodic maintenance, cleaning, and inspection. Moisture and contamination may build up inside the forkdepending on the severity of riding conditions. To maintain top performance it is recommended that the fork be periodically disassembled,cleaned, dried and re-greased.

IMPORTANT: When filling the fork with grease through the grease ports it is important to note the grease is being forced betweenthe upper and lower bushing. If the area is overfilled the force of the grease may force the upper bushing and dust seal out.IMPORTANT: Before every ride you should:1. Ensure that quick release skewers are properly adjusted and tight.2. Wipe the inner legs clean, lubricate and check entire fork for any

obvious damage.3. Check headset adjustment.4. Insure that the front brake cable is properly seated in the cable

retainer & check brake adjustment.

FIGURE 7: LUBRICATING THE BUSHINGS

IMPORTANT: Maintaining the proper oil level in your TPC is very important. Not enough oil will allow foaming and reduce theperformance. Too much oil will restrict travel and may cause damage to the system and an unsafe riding situation. Finish readingthis entire section prior to making any changes to the oil level.

To check the oil level remove only the compression assembly located in the top ofhe left leg. Leave the left side compression stack (adjuster, MCU, springssembly) in place to keep the fork fully extended. Use a tape measure or “diptick” to determine the oil level. Oil level should be between 3.50” (88.6mm) and.75” (120.6mm) below the top of the crown where the damping assembly screwsn. For all SX models with Lok-out the oil level should be between 3.75” (95mm)nd 4.25” (1.08mm). The recommended starting oil level is 4.00” (101mm). Use

SAE 5WT for oil. (See Figure 10.)

GENERAL DISASSEMBLY

NOTE: The Fork does not need to be removed from the bicycle for generaldisassembly-assembly or cleaning. It is also not necessary to disassemblehe 2000 Manitou Forks for compression Elastomer replacement.

Elastomer replacement is accomplished by removing the adjuster assemblyper Figure 12.

Removal of outer leg / arch assembly Figure 9:. Use a 4MM allen wrench to remove the M5 lower compression rod

screw from the left leg dropout. Pop out the damping adjuster knob from theright dropout, SXR. A small screwdriver may be helpful. Use an 8MM Allenwrench to remove the dropout nut. Fully compress the fork to prevent thecompression rod and damper shaft from turning while removing screws.

FIGURE 8: TPC OIL LEVEL

2. Pull outer leg assembly down to remove from theinner legs and crown.

3. Remove fork boots.4. Bushing replacement will require the use of the

bushing removal and installation tool availablefrom Answer Products. It is recommended thatthe bushings be left installed unless theyabsolutely need replacement.

Note: It is not recommended to remove the dust sealevery time the fork is disassembled. The seal andbushings may be cleaned and re-greased in place.

Compression Stack & Compression Rod Removal Figure 10:1. Press the bottom clip off the compression rod.2. Slide off the rebound elastomer from left leg compression rod.3. Unscrew and remove the adjuster assembly by hand.4. Turn fork upside down to remove the compression rod. If forks

are installed on bicycle give the rod a quick upward thrust andcatch it as it pops up above the crown.

Lower Shaft Disassembly Figure 11:

Note: Lower Shaft disassembly is best done withthe fork removed from the bicycle. Disassemblyof the damping stack is not required unless youwant to change or replace the shim stack.

1. Remove the left cap compression dampingassembly from the top of the fork leg and pourthe oil out of the top of the fork and discard

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appropriately. For complete disassembly continue.2. Remove the plastic end cap and pull the lower shaft out of the

inner leg.3. Remove the clear plastic detent sleeve and capture the 1/8” dia.

Detent ball used on SX R only.4. SX R adjuster needle may be unscrewed from the shaft.5. For SX R use 5MM allen wrench to remove piston seat. Keep note

of the exact order of the shims and spacers.

Compression Damping Disassembly Figure 12:1. The compression damping assembly is almost identical to the

lower shaft assembly.2. Unscrew the compression damping adjuster all the way until it

stops. The knob and the needle do not need to be removed. Theshaft also does not need to be removed from the cap. The threadsare bonded to prevent leaking.

3. Remove either the valve nut or the piston seat following theinstructions above for the lower shaft assembly.

FIGURE9: OUTER LEG REMOVAL

FIGURE 10: COMPRESSION STACK

FIGURE 11: LOWER TPC SHAFT ASSEMBLY

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FIGURE 12: TPC COMPRESSION DAMPING ASSEMLBY

DAMPER INSPECTION1. Check the shaft for scratches, wear, or other obvious damage.2. Check the seal gland and end cap seal grooves for damage.4. Check shims for permanent bends or damage.5. Check all other parts for obvious damage, replace if necessary.6. Replace all seals that have been removed.

FORK INSPECTION1. Check the fork boots for obvious damage.2. Check the dust seal for tears, wear, or damage. Replace if needed.3. Inspect the lower and upper bushing for damage to the Teflon coating. Replace using the bushing removal and replacement kits if

necessary.4. Check all MCU & springs for obvious damage. Replace if necessary.5. Check the preload adjuster and connectors. Replace if damaged.6. Check the outer leg/arch assembly for nicks or deep gouges on outside and inside. Replace if damaged.7. Check the inner leg for deep gouges and other damage. Minor wear resulting in color change is not detrimental to the gold anodized

surface. Replace if wear is excessive or damaged.8. Check inner legs at the bottom of the crown for cracks or for flaking anodize. Replace crown steer leg assembly if cracked or if gold

anodize is beginning to flake.9. Check the underside of the crown for cracks. Replace if cracked.

RE-ASSEMBLELower Shaft Figure 11:1. Install all o-rings and seals removed.2. Grease all seals lightly with seal grease.3. Apply small amount of blue Locktite to piston seat threads.4. Assemble shim stack and spacers in exact order that they were removed. For SX R hand tighten piston seat. Be sure large blow off

washer will slide over piston spacer and compress the small spring. Clamp shaft in soft jaws or collet and line up slots in clamp ringwith hole in piston seat using 1/8” or smaller pin. Use a 5MM Allen wrench and tighten piston seat by turning Allen wrench and pin atsame time. Torque 10 IN-LB (3.5 N-m) max.

5. SX R install lower needle gently into shaft, thread until it stops then back off one turn for initial adjustment.6. Slide shaft assembly through the plastic end cap, place detent ball in place and slide on 2nd STG Elastomer.7. Insert into left leg and thread in end cap. Torque 30 IN-LB (3.5N-m) max.8. Add approximately 90 CC of 5 WT Maxima or equivalent oil. Do not over fill. Check oil level, see Figure 8.

Compression Damping Assembly Figure 12:1. Reassemble compression damping stack following the instructions above for the lower shaft assembly.2. Install compression damping assembly into the left leg. The oil level should cover the compression valve when the assembly is installed.

Compression Rod & Boots Figure 13:1. Clean all parts thoroughly.2. Grease compression rod lightly. Be sure rebound Elastomer is installed onto compression rod.3. Drop compression rod down into inner legs. Shake inner leg to get rod through inner leg plug.4. Slide on black second stage, cup washer, and orange 3rd stage Elastomer.5. Slide Boots onto inner leg.

Outer Leg Assembly Figure 14:

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1. Slide Outer leg / Arch assembly onto inner legs and fully compress.

2. Install and torque 5MM compression rod screw anddropout nut to10-30 inch-lb. (1.1-3.5 N-m). Overtorquing the dropout nut may damage the dampershaft.

3. Pop in damper adjuster knob. O-ring holds knob inplace(SXR).

4. Slide skirt of fork boots onto the outer leg groove. Be surethe lip snaps into the groove.

5. Clean adjuster cap threads thoroughly. Clean threads oninside of inner leg.

6. Assemble MCU’s, springs, and connectors with thickgrease.

7. Install adjuster assembly into inner leg just hand tight.

INNER FORK LEGS & CROWN

The inner fork legs and steer tube are press fit into thecrown and may never be removed. Removing them willmake the fork unsafe to use. If you see any slippagecontact Answer Technical Staff immediately (800) 670-7446.

FIGURE 13: COMPRESSION ROD & BOOT

FIGURE 14: OUTER LEG ASSEMBLY

ADJUSTING RIDE QUALITIES2000 SX TPC forks offer a wide adjustment range to suit individual riding preference and rider weight by simply changing the MicroCellularUrethane (MCU’s). Fine tune adjustments can be made using the preload adjusters located on top of the fork crown. Softer blue and harderyellow MCU’s are available from your Dealer.NOTE: Since 2000 model forks use a compression stack in the left leg only, MCU’s and Springs used in previous Manitou forks are NOTinterchangeable with later versions of SX model Forks.

Compression Spring Fine Tuning: Figure 15Fine tuning adjustments to the spring rate are made by rotating the adjuster knobs located ontop of the crown. Note the 2000 SX LT, SX, and SX R uses compression spring systems inthe left leg only. Only the left knob on top of the crown adjusts preload. Rotating the knob

clockwise will firm the ride, adding preloadto the compression stack. Rotating theknob counter clockwise will soften the ride.

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Four full revolutions will take the adjuster from full soft to the extreme firm setting.

Compression Damping Fine Tuning: Figure 16To adjust the SX R simply rotate the compression damping knob located on top of the right legand crown. Rotating the knob clockwise will increase the damping, rotating the knob counterclockwise will reduce the damping. Excessive damping will give you a harsh ride over sharpbumps like rocky sections, but will feel good in large hits like G-outs. Insufficientcompression damping will bottom out in the large hit G-outs and bob a little while climbing butfeel plush on the sharp hits. A correctly adjusted fork will perform good in all conditions. TheSX LT and SX uses TPC Sport for compression damping and is not adjustable.

Rebound Damping Fine Tuning: Figure 17To adjust the SX R simply rotate the rebound damping knob located on bottom of the right leg.Rotating the knob clockwise will increase the damping, rotating the knob counter clockwisewill reduce the damping. Excessive rebound damping will give you a harsh ride over repetitivebumps (like braking bumps) because the fork will pack up. Insufficient rebound damping willmake the fork over active, top out and slap back when landing from a jump. We suggest thatyou try adjusting your fork on the very active side, minimum rebound. Then try it over avariety of terrain and tune in more rebound from there. The SX LT and SX uses TPC Sport forRebound damping and is not adjustable

Lok-Out System Kit P/N 85-8989Lok-Outs are available for all SX models. By turning the knob _ turn CCW, exposing the greensticker; the front fork will have regular TPC suspension. By turning the knob _ turn CW,exposing the red sticker; the fork will be locked out. A safety blow off valve will open underextreme conditions to allow some movement. To adjust the compression damping when notusing the Lok-Out. Remove the compression damping assembly from the top of the right leg.Adjust the setscrew, located in the valve seat, in to increase the damping and out to reduce thecompression damping. Try adjusting one _ turn at a time.

For additional tuning tips we recommend that you obtain a copy of the MRD tuningManual P/N 85-3485 and check out the MRD Race Tuning kits available at your dealer.

FIGURE 15: PRELOAD

FIGURE 16: COMPRESSION DAMPING

FIGURE 17: REBOUND DAMPING

TROUBLE SHOOTING

Fork seems to "top out" or has a slight clunking feel when front wheel comes off the ground:Excessive preload or insufficient rebound damping will result in a "top out" . Select MCU’s that better fit your weight and riding style, havingthe preload adjuster set mid to low range, and increase the rebound damping to eliminate "top out".

The fork feels less active and is not getting the travel it used to when it was new:Chances are that the fork is developing stiction. Cleaning and applying light oil to the stanchions will help.

Outer legs feel loose on inner legs and bushings, a knock or rock can be felt when pushed from side to side:A very small knock is normal with the new harder bushings. If the knock is excessive or you can feel the fork rocking then the bushingsshould be removed and replaced. To do this you must have the Answer Products Bushing Removal and Replacement Tool Kit.

A small amount of oil seems to be leaking from top of the left leg at the adjuster cap:If the 2000 SX us store upside down for a period of time a small amount of oil may leak through the adjuster cap / knob assembly. The caparea is not subjected to damping pressure. A small leak in that area will not affect the performance of the fork or cause any type of damage.

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We recommend that you store your Manitou left side up. If this condition causes you some problems please contact your Answer Productsdealer or call our warranty tech department for prompt service.

CYCLE COMPUTER INSTALLATION INSTRUCTIONS:Follow the instructions in your owners manual with the following exceptions:

WARNING: DO NOT DRILL A HOLE IN THE DROPOUT. THIS MAYWEAKEN THE DROPOUT, WILL VOID THE WARRANTY, AND MAYCAUSE AN UNSAFE CONDITION WITH RISK OF INJURY. DO NOT USETHE TEMPLATE PROVIDED IN THE 95 OR 96 SERVICE MANUAL.

2000 SX SERVICE MANUALP/N 85-3688

ANSWERANSWER PRODUCTS

28209 AVENUE STANFORD, VALENCIA, CA 91355(661) 257-4411

www.answerproducts.com